A Wallaby of my own.

[vcutajar]

Following you along Dave.

Vince

[steamer]

Thanks Vince!

Dave

[steamer]

OK ...got the mains line bored.....here's the photos....first make a boring bar for the little boring head.

Because I had the mill tied up, and this would be a BIG job on the Aciera...I milled the boring bar out of 3/8 0-1.   first I turned 1 end to 8mm to match the boring head , and then cut the bar long enough to get through the block...then I took out one of my secret weapons!

My cross drilling fixture.   It's a large steel block which mounts to my AXA wedge post, and then has 2 veeways cut in it by the lathe it is used on.    Because it is cut in place, the Vees are dead on center with the spindle.   Great for cross drilling shafts!....but...it can be used for other things.   In this case it becomes a milling vise to make the boring bar.   First I cut 1 end down by half.



Then I turned the bar in the vise, and made a relief cut down one side.


A quick undercut to put some relief on the back and ready to go.   Next I heated the cutting end to cherry red...and quenched in motor oil....
Ready to grind.


NOW>>>>Listen!

To sharpen this on a bench grinder you must go VERY slowly, if you put enough heat into the part to discolor it, your tempering it...and that will soften the tool...we really want it good and hard...so a little touch...cool in water..repeat...you'll get there

I don't temper my cutters anymore...they hold up just fine, and they hold their edge well...





All done!


Next ...time to bore the cam tunnel...its' set up so I'm just going for it!

Dave

[Mosey]

Dave,

You're the man! Fine and original work.

Mosey

[Don1966]

Dave thanks for the photos, I really like that setup. Great job as usual keep it coming bud.

Don

[steamer]

Thanks Guys...I hope it was instructive to someone.

Dave

[swilliams]

Nice Dave, making boring bars look easy. I've always turned them offset in the 4 jaw, but your way has got to be easier.

Steve

[steamer]

Perhaps rude crude and socially unacceptable...but they work

Thanks for the interest guys.

Dave

[steamer]

OK got the cam tunnel bored and co-bored.   Seems like the casting is spot on for this feature....all in all a good set of castings here

Feel free to pipe in Bez!

Here we are.

Roughed out with a long series 5/8 endmill


and bored


I wanted to put the idler gear bore in, but I need the cover, and some stub shafts...ect...so I just took her out of the vice but left it on the plate.

I started in on roughing out the head...though no pictures yet....I also need to get the gear cover sorted and ready to mount.   
The sump needs to roughed out to clear the bearing caps, and bored...I don't know which way I'll go with that, but I'll probably finish it on the lathe with the block on an arbor.

we progress.

Dave

[steamer]

Got the head squared up and ready...need to punch the holes to hold it.
Need to make a fixture plate for it

I cleared the sump to clear the bearing caps.   I found an error in Westbury's drawings.   The rear boss could be larger in diameter....the casting is to print...but it doesn't allow for the screws holding the mains.

I'll bleed on the print and get it back to you Bez...Nothing catastrophic though....Again...not structural so we can add some to the boss to put some meat in there for the rear seal plate to bolt and seal to.

Did you run into this Metalmad?

Dave

[steamer]

Probably the first thing I'll do once I make the fixture plate....



That way I can mount it to the fixture plate,...which will be mounted to the rotary table amoung other things

The central 2 holes will go in after once I get the exhaust ports cut....they are really tight to print...I may mover the studs slightly to clear them more easily.

Dave

[arnoldb]

Good progress Dave 

And a nice write-up on making a cutter from drill rod as well, especially the tip on not letting it discolour while grinding.

Kind regards, Arnold

[Mosey]

Impressive! Keep it coming.
M.

[steamer]

Thanks guys.....We'll get her done!

Dave

[steamer]

Holes in



I wish I got my DRO a lot sooner.....

Dave